MCP bunks are produced on a high volume packerhead
machine. This machine packs concrete against an outside
form while toweling the inside surface automatically for
a smooth finish.

How They
Are Made...We are often asked questions about our feed bunks. How are they made? What materials do we use? How strong are they, and do they deteriorate? Why do we claim that they are superior to wet-cast concrete bunks? These are all good questions, and we thought you might like to have some answers.

As you know, concrete feed bunks are available in a variety of shapes, sizes and lengths; however, there are only two methods of manufacturing concrete bunks, a slip form/wet cast method or a dry-cast method, which is what MCP utilizes.

MCP bunks are produced on a high volume packerhead machine. This machine packs concrete against an outside form while toweling the inside surface automatically for a smooth finish. This toweling results in a sealed surface that resists the effects of acidic rations as well as ice, snow and other elements. The wet-cast method utilizes forms on all surfaces; in turn, the feeding surface is porous and unfinished, and is much more susceptible to decay and deterioration.

The concrete we use in our dry-cast bunks has virtually no slump (8 sacks of cement per cubic yard). We use just enough water in the mix to chemically complete the hydration process. Because of the packing effect during production, and the minimum amount of water used, a high density, high strength product results. When core samples of our bunks are compared to a typical ready-mixed (wet-cast) bunk, the difference is clear. Our bunks prove the greater density by comparison of unit weight and absorption. (The more water used in concrete the more voids there are when the concrete cures).

What does this mean to a cattle feeder like you? It means that denser material exhibits less porosity (interconnected water voids) and is much less susceptible to ensilage or other acidic feeds. Of course, when the bunk does not absorb the acid or other corrosives, you can expect a much longer service life.

Another important part of the dry-cast method is the curing process. Our bunks undergo and eight (8) hour steam cure after production. Steam curing prevents the loss of water in the concrete which, in turn, insures that the hydration of all cement in the mix. Again, this translates into a very high strength (9200 psi), durable concrete bunk. Wet-cast/slip-form products are at the mercy of nature to affect a curing process. Concrete cured in hot, windy or cold conditions results in a product with less strength and more cracking.

The steel reinforcing in our bunk consists of welded wire fabric with approximately 3/16” round vertical bars on 6” centers, and the same size horizontal round bars on 2” centers. The steel reinforcing is placed approximately 1” from the outside wall of the bunk.

As you can tell, we think these feed bunks are the best available anywhere. Hundreds of thousands of feet of installed bunks and thousands of satisfied customers attest to this same belief. If you have any questions regarding our quality dry-cast feed bunks or would like to learn more about our delivery and installation procedures, please feel free to call 800-999-8151, or 620-241-4362. We would be happy to hear from you.